November 11, 2022

Many non-woodworkers cannot readily distinguish between a dovetail joint and a box joint. Many would not even know what a dovetail joint and box joint are. Yet, to give outsiders to woodworking an inside view into woodworking joints, the dovetail joints and the box joints are two distinct types of joints. Of course, a box joint is less complicated than a dovetail joint, and if you are a beginner in woodworking, you can first try making box joints.
A box joint is a type of joint made by simply cutting a complementary and interlocking set of profiles in two wood pieces. You can join these two wood pieces at right angles and use glue to strengthen the joints further. Since the box joint offers a larger gluing surface area than a butt joint, it results in a solid bond. You can use this joint for any box-like constructions and box corners. For this reason, it got its name. The box joint doesn’t exhibit similar interlocking properties as that of the dovetail joint, but it is easier to create.
What is the Optimal Thickness Ratio of Joint Finger to Wood?
The box joint is most robust if the fingers’ thickness equals the material’s thickness. If you use a wood stock around ¾” thick, the fingers should be at least 3/8” thick. With this thickness, you can expect this joint to be very strong, similar to the strength of the through dovetail joint.
This strength is due to the snugly fitting fingers, and the larger surface area glued. The box joint also exhibits a clean and neat appearance. It also exudes a utilitarian look ideal for office bins, shop toolboxes, and kitchen containers.
Applications and Uses of the Box Joint
As an aspiring woodworker, knowing how to make a box joint can further raise your woodworking skills a notch. But before you learn how to make a box joint, it will be best to know the following different uses of the box joint:
Wooden Carcasses and Boxes
You can use the box joint in making wooden carcasses and boxes. You can use it for making right-angle joints, but you can also use it for unusually shaped projects and hexagonal boxes. Besides, you can use it for drawer’s and lid’s sides. But it will not be advisable to use it for jointing thin panels with structural parts.
Drawers
You can use the box joint to make sturdy drawers which is the most common usage of this joint. You can make drawers for cupboards or desks using this joint. Plus, the box joint will stabilize your drawers, allowing them to remain in shape over time. You can also use this joint for drawers of your customized closets.
Carcasses
You can use box joints to make carcasses as basic box frames for large cabinets, bookcases, and drawer chests. Such carcasses can serve as skeletons before you add the doors or shelves. Since box joints are strong, you can expect these joints to keep secure the carcasses’ sides.
How to Make Box Joint?
You can make box joints manually using traditional hand tools like a tenon saw or a chisel. Yet, if you want precision, you can use a router or a table saw. These two tools can do the job for you efficiently. Besides, making box joints becomes easier, quick, and more precise compared to manual cutting.
Box joint is relatively easy to make. You only need to use the same profiles, but these profiles should be displaced for both wood. In most modern woodworking shops, box joints are made using a table saw equipped with a dado set. Besides, if you have custom machinery, you can make the entire joint in a single pass using a useful jig. The use of jigs enables you to make consistent cuts and results.
Manually or Using Power Tools
Box Frames
You can also use box joints to make wood boxes and other box projects. It is perfect for jewelry boxes, open-topped toolboxes, crates, and toy chests. Moreover, this joint is best suited for making various ranges of wooden boxes.
You can cut finger joints manually using the ordinary chisel or tenon saw. Yet, if you got power tools like a table saw and router, you can machine the whole joint. Make sure the halves are almost identical, save for every half’s last and first fingers. This calibrated offset lets the fingers entwine together.
If you want a clean joint, you should avoid tear outs at each finger’s base. Make sure you delineate a line across the fingers’ base. You can sand away the scribed line or leave it alone.
You can also avail of commercial fixtures and jigs to let you cut this type of joint with incredible precision. Yet, even if you use improvised jigs, you can still achieve almost the same results. The mastery of the box joints can serve as a good starting point for the mastery of the dovetail joint.
How to Make Box Joint?
You can make box joints manually using traditional hand tools like a tenon saw or a chisel. Yet, if you want precision, you can use a router or a table saw. These two tools can do the job for you efficiently. Besides, making box joints becomes easier, quick, and more precise compared to manual cutting.
Box joint is relatively easy to make. You only need to use the same profiles, but these profiles should be displaced for both wood. In most modern woodworking shops, box joints are made using a table saw equipped with a dado set. Besides, if you have custom machinery, you can make the entire joint in a single pass using a useful jig. The use of jigs enables you to make consistent cuts and results.
Aside from understanding what box joints are and how you can cut box joints, it will also help if you are familiar with the following tools needed to make a box joint:
1) Using a Router
You can either use a handheld router or a router mounted on the table. You will need a straight bit and a jig using the handheld router. You can also use a template that comes with some dovetail jigs. When buying, it will be best to ask the manufacturer if the dovetail jig comes with a template. However, if you don’t can’t buy a dovetail jig, you can improvise by making a DIY router jig.
You can also use a store-bought jig mounted to a beam to let you cut ¾” to 1/2” pins. You need to attach the adjustable bushing to the router’s base, and this bushing follows the comb-like jig’s teeth enabling you to cut sockets and pins. You can adjust the bushing to fine-tune the fit of the joint.
2) Using a Table Saw
You can use a table saw to cut box joints. This table saw should be equipped with a box-joint jig. This jig can be a DIY or a store-bought jig. If you’re an expert woodworker, you will build your jig instead of buying a store-bought jig.
Many DIY jigs utilize an indexing pin or key. This indexing key features the same width as those of the fingers, allowing you to position the workpiece well and adequately space the fingers’ width.
Once you’ve cut the first finger, you can place the space left by cutting over your indexing pin. This way, you can correctly position your wood piece for the succeeding cut. You must repeat this process until you have cut all the fingers.
You can also use a dado set or stacked dado blade along with your table saw. This blade is best for cutting dadoes, slots, or grooves into the wood. Dadoes are perfect for joinery. You can make slots or create rabbets that could fit two wood pieces together. You can also use dado blades to make box joint fingers.
3) Using a Router Table
You can also make box joints using a router table. You can cut box joints using a router table with the help of a sliding jig similar to the one used for your table saw. You can also use a jig that you can clamp to the router table’s top.
You can use a multi-joint spacing system to cut fingers about1/2”, 3/8”, and ¼” wide. This multi-joint spacing system comes with a fence that you can clamp to the router table’s top. It also has a right-angle block that lines the guide rail of the fence to support your workpieces while you pass them over the bit.
You can also use a box-joint jig for the router table. This jig is ideal for router tables and works like the table saw jig. Nevertheless, it cuts with the help of the router bit instead of a table saw blade.
You can set up the indexing key of the router table jig to position the workpiece at the precise position before making cuts after you’ve cut the first finger. You only need to repeat this procedure until all the fingers are cut.
Useful Tips When Making Box Joint
Aside from knowing the tools you can use for making box jointS, it will also help if you are familiar with the following tips. This way, you can make your box joints stronger and sturdier:
- Ensure you keep the pins about half the material thickness or less. However, if you’re dealing with narrow workpieces, ensure you got three pieces or more on any of the pieces you would like to join.
- You should use a chisel or dovetail saw when making box joints manually.
- You should use a spiral bit when you’re working on a router table. This way, you can reduce tear-out.
- Keep your workpiece pressed firmly against the table saw fence. You can clamp bigger workpieces to the fence, especially the heavy ones. This way, you can work safely and accurately.
- Ensure the workpiece’s end is flat against the surface to produce accurate cuts.
- Inspect each matching set to ensure that they fit perfectly.
- Build your box joint jig if you don’t want to consume too much time. With this jig, you can ensure you can make consistent cuts.
- Your box joints should naturally slip together manually. It is okay if there is a bit of friction. But if the fit is too tight, you will find it hard to glue the pieces. Nevertheless, you cannot secure the pieces together if it is loose.
- Apply glues on both sides to ensure maximum hold.
What is the Difference between Dovetail Joints and Box Joints?
As mentioned above, if you’re an outsider to woodworking, you might fail to distinguish between dovetail and box joints, because both joints feature interlocking fingers and alternating profiles. If the profile cuts are trapezoidal, it is a dovetail joint. This design lets the pieces lock together like jigsaw puzzle pieces.
The angular design of the dovetail joints provides more strength and exhibits a higher level of craftsmanship. Box joints, on the other hand, have rectangular pins that slide together in whatever direction.
Conclusion
Box joints are suited for joining boards, wider slats, and solid panels. They are also simple and more straightforward to do than the dovetail joints. They offer rigidity and strength as well as enhance appearance. Moreover, you can disassemble them by steaming the wood to soften adhesive or glue. You can also use fasteners and glue to strengthen the joints further.
The box joint is relatively new. Yet, it is a solid joint that makes it ideal for making tool chests and boxes. So, learning how to make this joint can enhance your woodworking skills and raise your woodworking endeavors a notch.

Liam is a 37-year-old woodworker and interior designer who loves to make every furniture project an art piece. He is very experienced in furniture design and woodworking project planning.